Method of making an aerosol dispenser having annular seals and method of making an aerosol container therefor

ABSTRACT

A method of making an aerosol container suitable for use as an aerosol dispenser. The aerosol container includes at least a valve and product delivery device joined to an outer container. The method has the steps of sealing the valve to the product delivery device and outer container at respective annular welds or other bonds joining the valve to the product delivery and to the outer container. The welds, or other bonds may be concentric, with one circumscribing the other, in the same plane or different planes. Suitable product delivery devices include bags and dip tubes. Suitable welds include spin welds.

FIELD OF THE INVENTION

The present invention relates to welded aerosol dispensers andcomponents for the manufacture thereof.

BACKGROUND OF THE INVENTION

Aerosol dispensers are well known in the art. Aerosol dispenserstypically comprise an outer container which acts as a frame for theremaining components and as a pressure vessel for propellant and productcontained therein. Outer containers made of metal are well known in theart. However, metal containers can be undesirable due to high cost andlimited recyclability. Attempts to use plastic have occurred in the art.Relevant attempts in the art to employ plastic in aerosol dispensers arefound in U.S. Pat. Nos. 2,863,699; 3,333,743; 4,969,577; 8,752,731;9,296,550; 9,334,103 and 2009/0014679.

The outer containers are typically, but not necessarily, cylindrical.The outer container may comprise a bottom for resting on horizontalsurfaces such as shelves, countertops, tables etc. The bottom of theouter container may comprise a re-entrant portion as shown in U.S. Pat.No. 3,403,804 or a base cup as shown in commonly assigned U.S. Pat. Nos.8,439,223 and 9,061,795. Sidewalls defining the shape of the outercontainer extend upwardly from the bottom to an open top.

The open top defines a neck for receiving additional components of theaerosol dispenser. The industry has generally settled upon a nominalneck diameter of 2.54 cm, for standardization of components amongvarious manufacturers, although smaller diameters, such as 20 mm, arealso used. Various neck shapes are shown in U.S. Pat. Nos. 6,019,252;7,028,866; 7,279,207 and 7,303,087.

Typically a valve cup is inserted into the neck. The valve cup is sealedagainst the neck to prevent the escape of the propellant and loss ofpressurization, such as described in U.S. Pat. Nos. 8,074,847;8,096,327; 8,844,765; 8,869,842 and 9,505,509. The valve cup holds thevalve components which are movable in relationship to the balance of theaerosol dispenser. Suitable valves are shown in commonly assigned U.S.Pat. Nos. 8,511,522 and 9,132,955. When the valves are opened, productmay be dispensed through a nozzle, etc. as described in commonlyassigned U.S. Pat. No. 9,174,229.

A valve may be inserted into the valve cup for selective actuation bythe user. The valve is typically normally closed, and may be opened tocreate a flow path for the product to ambient or a target surface. Thevalve may be compatible with local recycling standards. Suitable valvesare disclosed in commonly assigned U.S. Pat. Nos. 8,511,522 and9,132,955.

If a valve is to be assembled into an aerosol, typically the valve cupis crimped onto the neck of the aerosol container. But this operation isexpensive and is difficult to perform with a plastic valve cup. Aseparate interlock may be used to attach a valve to a valve cup,particularly a plastic valve 28 and plastic valve cup are used. Suitableinterlocks include bayonet fittings and threads as disclosed in commonlyassigned P&G Case 14458, Ser. No. 15/235,237, filed Aug. 12, 2016. Apressure vessel with a threaded bore is proposed in U.S. Pat. No.8,505,762.

A bag may be used to contain product for selective dispensing by a user.Dispensing of product from the bag occurs in response to the useractuating the valve. The bag separates product within the bag frompropellant disposed between the bag and container. This bag limits oreven prevents intermixing of the contents of the bag and the componentsoutside of the bag. Thus, product may be contained in the bag.Propellant may be disposed between the outside of the bag and the insideof the outer container. Upon actuation of the valve, a flow path out ofthe bag is created. This embodiment is commonly called a bag in can andmay be used, for example, in dispensing shaving cream gels.Alternatively, a bag may be directly joined to the valve housing, in aconfiguration commonly called a bag on valve. A suitable bagconfiguration is disclosed in commonly assigned P&G Case 14458, Ser. No.15/235,227, filed Aug. 12, 2016 which teaches attaching a bag to a valvecup.

If a bag configuration is desired, propellant may be disposed betweenthe bag and outer container, as disclosed in U.S. Pat. No. 5,219,005 andin commonly assigned U.S. Pat. Nos. 8,631,632 and 8,869,842. Afterwards,product fill may occur in a separate, remote, operation, optionallycarried out in another location, which may be in the same country or ina different country commonly assigned 2012/0291911. Such a manufacturingprocess can conserve costs in production, shipment and/or storage.

An aerosol container having a bag therein may be made from a dual layerpreform, having plural layers disposed one inside the other. Relevantattempts include U.S. Pat. Nos. 3,450,254; 4,330,066; 6,254,820; RE30093 E; WO 9108099 and US 2011/0248035 A1. But each of these attemptsrequires a separate operation to attach the bag to the relevantcomponent. Each attachment step takes time in manufacturing and createsthe opportunity for leakage if not correctly performed. Improvements indual layer preforms are found in commonly assigned P&G Case 14461,application Ser. No. 15/235,279, filed Aug. 12, 2016.

Alternatively, a dip tube may be used if intermixing of the product andpropellant is desired. When the user actuates the valve, the product andpropellant are dispensed together through the dip tube. This embodimentmay utilize a dip tube. The dip tube takes the product and propellantmixture from the bottom of the outer container. Or a piston may be usedto expel product, particularly if highly viscous, as described in2002/0027146, U.S. Pat. No. 6,375,045 and commonly assigned2016/0368700.

Collectively, bags, dip tube, pistons and the associated hardware arereferred to as product delivery devices. Various formats for thedelivery devices may be required for different products, oftencomplicating production. For example, one product may require a dip tubeproduct delivery device in conjunction with a very small nozzle. Thenext aerosol dispenser on the production schedule may simply requirechangeout to a new, larger, nozzle.

But if one wishes to then manufacture an aerosol dispenser utilizing abag for a particular production cycle, then manufacture an aerosoldispenser having a dip tube, for subsequent production cycles,considerable changeout is required. Different outer containers aretypically needed to accommodate the different product delivery devices.Likewise, different valves are likely required. As different valves arerequired, the different outer containers must be matched to accommodatethe different valves. Different valves may also require different valvecups which can be plastic and welded into place, be metal and crimpedinto place or no valve cup at all may be needed. A combination of outercontainer, valve, product delivery device and associated hardware, ifany, is referred to as a format for a particular aerosol dispenser.

The numbers of components required for even a few different formats candramatically increase as different products are produced in respectiveaerosol dispensers. Such increase dramatically raises production costsand increases the opportunity for mistakes. Accordingly this inventionsimplifies production of aerosol dispensers when different aerosoldispenser formats are sought by using plural welds.

SUMMARY OF THE INVENTION

In one embodiment the invention comprises a method of making an aerosoldispenser, or an aerosol container for an aerosol dispenser. Eachembodiment has an aerosol container having a longitudinal axis andcomprising: an outer container comprising a closed end bottom and anopen neck longitudinally opposed thereto. The method has the steps ofsealing a valve welded to the outer container in fluid tightrelationship by an outer container weld and sealing a product deliverydevice to the valve in fluid tight relationship by a product deliverydevice weld. The product delivery device weld is radially spaced apartfrom the outer container weld.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are to scale, unless otherwise noted as schematic.

FIG. 1 is a side elevational view of an aerosol dispenser according tothe present invention, showing an actuator and spray being schematicallydispensed from a nozzle, the actuator and nozzle being omitted from allsubsequent figures.

FIG. 2 is a top plan view of an aerosol container suitable for use withthe aerosol dispenser of FIG. 1.

FIG. 3A is a vertical sectional view taken along line 3-3 of FIG. 2 andshowing the inner bag in its state as a preform.

FIG. 3B is a vertical sectional view taken along line 3-3 of FIG. 2 andshowing the inner bag in its blow molded state as a bag.

FIG. 4A is a side elevational view of a preform suitable for use withthe present invention.

FIG. 4B is a vertical sectional view taken along lines 4B-4B of FIG. 4A.

FIG. 4C is a fragmentary enlarged view of the preform of FIG. 4B.

FIG. 5A is a top perspective view of a valve usable with the presentinvention.

FIG. 5B is a side perspective view of the valve of FIG. 5A.

FIG. 5C is a bottom perspective view of the valve of FIG. 5A

FIG. 6A is a top plan view of a preform suitable for use with thepresent invention and having a valve thereon.

FIG. 6B is a side elevational view of the valve and preform of FIG. 6A.

FIG. 6C is a bottom plan view of the valve and preform of FIG. 6A.

FIG. 7A1 is a vertical sectional view of the preform and valve of FIG.6A having a bag for the product delivery device welded to the preformand showing the valve in the closed position.

FIG. 7A2 is an enlarged fragmentary view of the valve and preform ofFIG. 7A1.

FIG. 7B1 is a vertical sectional view of the preform and valve of FIG.7A1 prior to welding with the protrusions in position, the bagprotrusion depending lower than the outer container protrusion andshowing the valve in the open position.

FIG. 7B2 is an enlarged fragmentary view of the valve and preform ofFIG. 7B1.

FIG. 7C1 is a vertical sectional view of an alternative embodiment ofthe preform and valve of FIG. 6A having a dip tube for the productdelivery device with the protrusions in position, the dip tubeconcentrator depending lower than the outer container protrusion.

FIG. 7C2 is an enlarged fragmentary view of the valve and preform ofFIG. 7C1, showing the valve and dip tube welded into position.

FIG. 8A is an enlarged fragmentary perspective view of an outercontainer having generally parallel first surface and second surface,both oblique to the longitudinal axis.

FIG. 8B is an enlarged fragmentary perspective view of the embodiment ofFIG. 8A having a bag inserted therein for a product delivery device.

FIG. 8C is an enlarged fragmentary perspective view of the embodiment ofFIG. 8A having two coaxial bags inserted therein for a single productdelivery device and showing an optional dip tube in the single productdelivery device.

FIG. 9 is an enlarged, instantaneous fragmentary sectional view of anouter container having contiguous and coplanar first and second sealingsurfaces generally perpendicular to the longitudinal axis and not havingan optional seal therebetween.

FIG. 10 is a schematic fragmentary sectional view of a neck of an outercontainer and bag, each having an upwardly projecting protrusion.

FIG. 11A is a vertical sectional view of an outer container, valve andbag in position for joining.

FIG. 11B is a vertical sectional view of the outer container, valve andbag of FIG. 11A after welding, and showing a schematic external driveand schematic chuck.

FIG. 12 is an image of a vertical section view of an outer container,valve, and product delivery device before welding.

FIG. 13 is an image of a vertical section view of the outer container,valve, and product delivery device of FIG. 12 after spin-welding to aweld depth of 0.4 mm.

FIG. 14 is an image of a vertical section view of the outer container,valve, and product delivery device of FIG. 12 after spin-welding to aweld depth of 1.0 mm.

FIG. 15 is an image of a vertical section view of the outer container,valve, and product delivery device of FIG. 12 after spin-welding to aweld depth of 1.8 mm.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, an aerosol dispenser 20 having alongitudinal axis is shown. The aerosol dispenser 20 comprises apressurizeable outer container 22 usable for such an aerosol dispenser20. The outer container 22 has a neck 24 into which a valve cup 26 issealingly disposed. A valve 28 and actuator 29 may be disposed in thevalve cup 26 for selective dispensing of product 42 from the aerosoldispenser 20. A seal having a surface for sealing a valve 28 to thevalve cup 26 may be disposed below the valve cup 26 and valve 28 toprevent escape of product 42 to ambient. As used herein, an aerosolcontainer 20C may be a subset of an aerosol dispenser 20, and have anouter container 22, valve cup 26 sealed thereto with a bag 55/dip tube56, collectively referred to as a product delivery device 55, 56, joinedto the valve cup 26, and optionally propellant 40, but not necessarily avalve 28, actuator 29, labeling 57, etc. Optionally the valve 28 may bedirectly joined to the outer container without a separate valve cup 26.

As used herein, the top of the aerosol dispenser 20 or the container 22is taken as the uppermost part, when the aerosol dispenser 20 orcontainer 22 is vertically oriented in its normal use or storageposition. As used herein, the bottom of the aerosol dispenser 20 or thecontainer 22 is taken as the lowermost part, when the aerosol dispenser20 or the container 22 is vertically oriented in its normal use orstorage position. The top and bottom are longitudinally opposed, withthe top typically being open and bottom typically being a closed end.The terms ‘above’ and ‘below’ refer to relative positions towards andaway from the top, respectively. Likewise the terms ‘above’ and ‘below’refer to relative positions away from and towards the bottom,respectively.

The aerosol dispenser 20 and outer container 22 have a longitudinalaxis, defining the main axis. The aerosol dispenser 20 and outercontainer 22 may be longitudinally elongate, i.e. having an aspect ratioof longitudinal dimension to transverse dimension[s] such as diametergreater than 1, an aspect ratio equal to 1 as in a sphere or shortercylinder, or an aspect ratio less than 1.

The outer container 22 may comprise metal or preferably plastic, as areknown in the art. The plastic may be polymeric, and particularlycomprise polyethylene terephthalate (PET) or polypropylene (PP) for allof the components described herein. The outer container 22 may beinjection molded or further blow molded in an ISBM process, as wellknown in the art. The outer container 22 defines a longitudinal axis andmay have an opening at one end thereof. The opening is typically at thetop of the pressurizeable container when the pressurizeable container isin its-in use position. The opening defines a neck 24, to which othercomponents may be sealingly joined.

As the top of the outer container 22 is approached, the outer container22 may have a neck 24. The neck 24 may be connected to the containersidewall by a shoulder 23. The shoulder 23 may more particularly bejoined to the sidewall by a radius. The shoulder 23 may have an annularflat. The neck 24 may have a greater thickness at the top of the outercontainer 22 than at lower portions of the neck 24 to provide adifferential thickness. Such differential thickness may be accomplishedthrough having an internally stepped neck 24 thickness.

A normally closed valve 28 may be disposed in the neck 24. The valve 28is openable upon demand by a user, in response to manual operation of anactuator 29. The actuator 29 may be depressable, operable as a trigger,etc. to spray product 42 from the aerosol dispenser 20. Illustrative andnon-limiting products 42 include shave cream, shave foam, body sprays,body washes, perfumes, cleansers, air treatments, astringents, foods,paint, insecticides, etc.

Referring to FIGS. 3A-3B, an optional valve cup 26 may be sealed to theopening of the outer container 22. The valve cup 26 may be sealed to theneck 24 of the outer container 22 using class 1 TPE material. Polyesterbased TPE sold by Kraiburg TPE GmbH & Co KG of Waldkraiburg, Germanyunder the name HTC8791-52 and sold by DuPont of Delaware under the nameHYTEL may be used for good resistance to Silicone and adhesion to PET.Such a TPE material is believed to fall under Resin Identification Code1/01 for PETE/PET, as set forth above by the Society of PlasticsIndustry and ASTM D7611. Or a Styrenic bloc copolymer based TPE such asKraiburg HTC8791-24 or Krayton elastomer may be used, providing easierprocess and lower density. Other seal materials include silicone, rubberand similar conformable materials.

If desired, the valve cup 26 may be sealed to the outer container 22utilizing a press fit, interference fit, solvent welding, laser welding,sonic welding, ultrasonic welding, spin welding, adhesive or anycombination thereof. An intermediate component, such as a sleeve orconnector may optionally be disposed intermediate the valve cup 26 andneck 24 or top of the outer container 22. Any such arrangement issuitable, so long as a seal adequate to maintain the pressure results.

Referring particularly to FIG. 3A, a preform 60 can be made in a singleinjection molding operation, providing tolerances suitable for massproduction. A first preform 60 is then blow molded in known fashion tomake the outer container 22. A valve attachment 25, such as threads, isabove the blow molding operation, preventing undue dimensionaldistortion thereof. A second preform 60 can be used to make the valvecup 26 as the finish and internal bag 55 as the body upon blow moldingthereof. One of skill will understand the blow molding step may alsoinclude stretching as is known in the art.

Referring particularly to FIG. 3B, the bag 55 can be integral with thevalve cup 26. By integral it is meant that the bag 55 and valve cup 26are monolithic, molded at the same time or molded of two differentmaterials melted together in a permanent manner. An integral bag 55 andvalve cup 26 cannot be separated into two components without tearing orundue deformation. A container 22 made from a preform 60 using ISBM isreferred to herein as a molded container 22.

Referring to FIGS. 4A, 4B and 4C, the preform 60 may be used to make theouter container 22 or a bag 55 for use with the aerosol dispenser 20 ofthis invention. One of skill will recognize a bag 55 is commonly used tocontain product 42 and keep such product 42 isolated from the propellant40.

Referring to FIGS. 5A, 5B and 5C, a valve 28, in turn, may be disposedwithin the valve cup 26. The valve 28 provides for retention of product42 within the aerosol dispenser 20 until the product 42 is selectivelydispensed by a user. The valve 28 may be selectively actuated by anactuator 29. A nozzle 27 and related valve 28 components may optionallybe included, depending upon the desired dispensing and spraycharacteristics. The valve 28 may be attached using conventional andknown means. The valve 28 and actuator 29 may be conventional and do notform part of the claimed invention. Selective actuation of the valve 28allows the user to dispense a desired quantity of the product 42 ondemand.

The valve 28 may provide for dispensing from the top of the bag 55/diptube 56 through one or more ports and into the valve stem. Optionally,the valve 28 may have a bypass outside the ports to accommodaterelatively viscous product 42.

A valve stem 28S provides a product 42 flow path and joins the actuator29 to the valve 28 in fluid communication. The valve 28 may have anupwardly projecting sheath 28P. The upstanding sheath 28P maycircumscribe and extend longitudinally beyond the valve stem 28S.Alternatively the upstanding sheath 28P may comprise three or morecircumferentially spaced upstanding struts, each of which longitudinallyextend beyond the valve stem 28S. Either geometry protects the valvestem 28S during storage and assembly. For example, if the aerosolcontainers 20C are solder stacked prior to product 42 fill and addingthe actuator 29, the sheath 28P protects the valve stem 28S from layersstacked on top.

Furthermore, the sheath 28P may have internal or external blades 28B.The blades 28B may assist in threadedly assembling the valve 28 to theouter container 22, or in spin welding the valve 28 to the outercontainer 22.

Alternatively or additionally, the sheath 28P may be cantilevered fromthe top of the outer container 22. In such an embodiment, the sheath 28Pmay be joined to the outer container 22 after blow molding.Alternatively, and preferably, the sheath 28P may be integrally moldedwith the preform 60. This arrangement eliminates an assembly step andthe possibly detachment.

Referring to FIGS. 6A, 6B and 6C, the valve may be inserted on a preform60. The preform 60 is blown into an outer container 22. The preform 60may be blown into the outer container 22 before or after the valve 28 isattached.

Referring to FIGS. 7A1, 7A2, 7B1, 7B2, 7C1 and 7C2, the product deliverydevice 55, 56 may be used to contain and/or provide for delivery ofproduct 42 from the aerosol dispenser 20 upon demand. Suitable productdelivery devices 55, 56 comprise pistons, bags 55, dip tubes 56, and donot form part of the claimed invention, except as specifically claimedherein. If desired, the product delivery device 55, 56 may furthercomprise a metering device for dispensing pre-determined, meteredquantities of product 42, as described in U.S. Pat. Nos. 2,815,889;4,142,652 and 5,421,492. The product delivery device 55, 56 may alsocomprise an inverting valve having a ball therein to alter product 42flowpath.

If desired the product delivery device 55, 56 may comprise a dip tube 56disposed in a bag 55. Such a dip tube 56 may reach to nearly the bottomof the bag 55, or be juxtaposed near the middle of the bag 55. A diptube may be made according to U.S. Pat. No. 8,091,741.

The pressurizeable container may further include a propellant 40. Thepropellant 40 may comprise hydrocarbons, nitrogen, air and mixturesthereof. Propellant 40 listed in the US Federal Register 49 CFR1.73.115, Class 2, Division 2.2 are also considered acceptable. Thepropellant 40 may particularly comprise aTrans-1,3,3,3-tetrafluoroprop-1-ene, and optionally a CAS number1645-83-6 gas. One such propellant 40 is commercially available fromHoneywell International of Morristown, N.J. under the trade nameHFO-1234ze or SOLSTICE.

If desired, the propellant 40 may be condensable. Generally, the highestpressure occurs after the aerosol dispenser 20 is charged with product42 but before the first dispensing of that product 42 by the user. Acondensable propellant 40, when condensed, provides the benefit of aflatter depressurization curve at the vapor pressure, as product 42 isdepleted during usage. A condensable propellant 40 also provides thebenefit that a greater volume of gas may be placed into the container ata given pressure. A condensable propellant 40, such as HFO-1234ze, maybe charged to a gage pressure of 100-400 kPa at 21 degrees C.

If desired, the outer container 22, valve cup 26, valve 28, and/orpiston may be polymeric. By polymeric it is meant that the component isformed of a material which is plastic, comprises polymers, and/orparticularly polyolefin, polyester or nylons, and more particularly PET.Thus, the entire aerosol dispenser 20 or, specific components thereof,may be free of metal, allowing microwaving. Microwave heating of theaerosol dispenser 20 or pressurizable container therefor provides forheating of the product 42 prior to dispensing. Heating of the product 42prior to dispensing may be desirable if the product 42 is applied to theskin, becomes more efficacious at lower viscosities, or is to be eaten.

The valve cup 26 may have a valve cup 26 periphery complementary to theneck 24 periphery. At least one of the valve cup 26 and/or containerneck 24 may have one or more channels therethrough. Additionally oralternatively, the channels may be formed at the interface between thevalve cup 26 and container neck 24. The channels may be formed byirregularities, such as crenulations, merlins, serrations, notches,teeth, etc. between valve cup 26 and/or container neck 24.

The outer container 22, and all other components, optionally exceptingthe TPE seal, may comprise, consist essentially of or consist of PET,PEN, Nylon, EVOH or blends thereof to meet DOT SP 14223. All suchmaterials may be selected from a single class of recyclable materials,as set forth above by the Society of Plastics Industry and ASTM D7611.Particularly all components of the aerosol dispenser 20 may comprise theaforementioned TPE and PET/PETE, Resin Identification Code 1/01. Thismaterial selection provides the benefit that the entire aerosoldispenser may advantageously be recycled in a single stream.

Alternatively, the valve cup 26 and/or bag 55 may comprise plural layerssuch as nylon with EVOH, PET and/or polyolefin materials. Three layersmay be utilized, such as PET/Nylon/PET or PET/EVOH/PET. The layers maybe co-molded or overmolded. The multi-layer arrangements may provideincreased barrier resistance and reduced failure rates.

Referring back to FIG. 1, the outer container 22, and/optionally theproduct delivery device 55, 56, may be transparent or substantiallytransparent. This arrangement provides the benefit that the consumerknows when product 42 is nearing depletion and allows improvedcommunication of product 42 attributes, such as color, viscosity, etc.Also, labeling or other decoration of the container may be more apparentif the background to which such decoration is applied is clear.

Suitable decoration includes labels 57. Labels 57 may be shrink wrapped,printed, etc., as are known in the art. Any label 57 which providesuseful and or aesthetic indicum for the user is acceptable andcontemplated herein.

The outer container 22 may define a longitudinal axis of the aerosoldispenser 20. The outer container 22 may be axisymmetric as shown, or,may be eccentric. While a round cross-section is shown, the invention isnot so limited. The cross-section may be square, elliptical, irregular,etc. Furthermore, the cross section may be generally constant as shown,or may be variable. If a variable cross-section is selected, the outercontainer 22 may be barrel shaped, hourglass shaped, or monotonicallytapered.

The outer container 22 may range from 6 to 60 cm, and particularly 10 to40 cm in height, taken in the axial direction and from 3 to 60 cm, andparticularly 4 to 10 cm in diameter if a round footprint is selected.The outer container 22 may have a volume ranging from 40 to 1000 ccexclusive of any components therein, such as a product delivery device55, 56. The outer container 22 may be injection stretch blow molded. Ifso, the injection stretch blow molding process may provide an overallstretch ratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15 or 20 and lessthan 50, 40 or 30.

The outer container 22 may sit on a base. The base is disposed on thebottom of the outer container 22. Suitable bases include petaloid bases,champagne bases, hemispherical or other convex bases used in conjunctionwith a base cup. Or the outer container 22 may have a generally flatbase with an optional punt.

A manifold may supply propellant 40, under pressure, through at leastone channel between the valve cup 26 and container neck 24. The manifoldmay be retractingly disposed above the container 22. The manifold may bebrought into contact with the valve cup 26, forming a temporary sealtherebetween. Suitable channels are particularly described in commonlyassigned U.S. Pat. No. 8,869,842 to Smith at FIG. 8, column 7, lines 57to column 8, line 2 and column 8, lines 44-60. While the temporary sealis established between the manifold and valve cup 26, the propellant 40may be charged into the outer container 22.

The aerosol dispenser 20, as presented to a user may have an initialpressure. The initial pressure is the highest pressure encountered for aparticular filling operation, and corresponds to no product 42 yet beingdispensed from the product delivery device 55, 56. As product 42 isdepleted, the outer container 22 approaches a final pressure. The finalpressure corresponds to depletion of substantially all product 42,except for small residual, from the product delivery device 55, 56. Onebenefit of the invention is that the residual product 42, remaining atend of life, is unexpectedly minimized.

This arrangement provides the benefit that propellant 40 may be chargedto a lesser pressure than the desired starting pressure, decreasingpropellant 40 charge time and reducing pressure applied to the chargingmachinery. Another benefit is that propellant 40 is disposed as neededfor the end use when the aerosol dispenser 20 is ready for sale, product42 fill and upon product 42 depletion may be recharged with product 42and reused.

At 21 degrees C., the outer container 22 may be pressurized to aninternal gage pressure of 100 to 1300, 110 to 490 or 270 to 420 kPa. Aparticular aerosol dispenser 20 may have an initial propellant 40pressure of 1100 kPA and a final propellant 40 pressure of 120 kPa, aninitial propellant 40 pressure of 900 kPA and a final propellant 40pressure of 300 kPa, an initial propellant 40 pressure of 500 kPA and afinal propellant 40 pressure of 0 kPa, and any values therebetween.

If a permanent seal between components of the aerosol dispenser 20 isdesired, the seal may be welded. Particularly, if the components havecompatible melt indices, such components may be sealed by welding toretain propellant therein. Welding may occur in either or both of theliquid and glassy phases, and may be optionally be assisted byapplication of compressive forces. Suitable welding processes mayinclude sonic, ultrasonic, spin, and laser welding. Welding may beaccomplished with a commercially available welder, such as availablefrom Branson Ultrasonics Corp. of Danbury, Conn. Alternatively oradditionally, the channel may prophetically be blocked by a plug orsealed by adhesive bonding. Suitable sealing processes are particularlydescribed in commonly assigned U.S. Pat. No. 8,869,842 to Smith at FIG.9 and column 8, lines 30-43.

Spin welding has been found to be particularly preferred. Spin weldingprovides the benefit that the energy plane is generally confined to asmall vertical space, limiting unintended damage of other components notintended to be welded or receive such energy. Spin welding furtherprovides the benefit that both the outer container weld 22W and the weld55W for the bag 55/the weld 56W for the dip tube 56 may occursimultaneously or nearly at the same time, increasing product speed.

Or if desired, the product delivery device weld 55W, 56W may occurfirst, providing a pressure boundary between the product delivery device55, 56 and the valve 28. During establishment of or once the pressureboundary has been established, the propellant 40 charge may occur,allowing for simultaneous welding and charging. After the productdelivery device weld 55W, 56W and propellant 40 charge occur the outercontainer weld 22W may be completed, providing for containment of thepropellant 40 within the outer container 22.

The timing of the product delivery device weld 55W, 56W occurring after,or preferably before the outer container weld 22W may be influenced byrespective protrusions 22E, 55E, 56E. Particularly the valve 28 may havea depending product delivery device protrusion 55E, 56E, circumscribingan outer container protrusion 22E. The if the protrusions equallycontact the respective mating surfaces, the product delivery device weld55W, 56W, and outer container weld 22W will generally simultaneouslyoccur. Preferably, the product delivery device protrusion 55E for thebag 55/56E for the dip tube 56 depends further than the outer containerprotrusion 22E, so that welding order allows for propellant charge 40 asdescribed herein.

If the product delivery device 55, 56 is a dip tube 56, the propellant40 charge and product 42 charge may simultaneously occur. The propellant40 and product 42 may be premixed into a single charge, which occursduring the welding operation. Alternatively either a bag 55 or a diptube 56 aerosol dispenser 20 may have the product 42 later added throughthe valve 28, as is known in the art.

A first annular sealing surface 31 is disposed below the valve 28 andhas a first sealing surface diameter FSD which is less than the valveattachment diameter, VAD. A second annular sealing surface 32 isdisposed below the first annular sealing surface 31 and has a secondsealing surface diameter SSD less than the first sealing surfacediameter FSD. The first annular sealing surface 31 may provide supportfor the valve 28, which may be disposed between the first annularsealing surface 31 and the valve 28. The second annular sealing surface32 may provide support for the product delivery device 55, 56, which maybe disposed between the second annular sealing surface 32 and the valve28.

The first annular sealing surface 31 may circumscribe the second annularsealing surface 32. The first annular sealing surface 31 may be in thesame plane as the second annular sealing surface 32, or may be in adifferent plane, particularly first annular sealing surface 31 may beabove the second annular sealing surface 32. The first annular sealingsurface 31 is disposed radially outward of the second annular sealingsurface 32.

The valve 28 is welded to the outer container 22 in fluid tightrelationship by an outer container weld 22W. The outer container weld22W occurs between the valve 28 and the first annular sealing surface31. Likewise, a product delivery device 55, 56 is welded to the outercontainer 22 in fluid tight relationship by a product delivery deviceweld 55W, 56W. The product delivery device 55, 56 weld occurs betweenthe product delivery device 55, 56 and the second annular sealingsurface 32. The product delivery device weld 55W, 56W is radially spacedapart from the outer container weld 22W.

If desired, the valve 28 may be welded to the second sealing surface 32directly or may be welded to the product delivery 55, 56. This assemblygeometry provides the flexibility for various geometries depending uponthe specific aerosol dispenser and product 42 combination desired.

The outer container 20C according to the present invention has two weldsa product delivery device weld 55W, 56W and an outer container weld 22W,which are mutually radially spaced apart from the other. If one or moreof the product delivery device weld 55W, 56W and outer container weld22W are relatively thick in the radial dimension, and spaced relativelyclose to the other, the product delivery device weld 55W, 56W and outercontainer weld 22W may appear to merge. Such an embodiment iscontemplated and within the scope of the present invention. While tworadially spaced apart welds 55W, 56W, 22W are shown, one of skill willrecognize that any plurality of welds may be utilized. Additional weldsmay be used to join additional components as desired or to reinforce theproduct delivery device weld 55W, 56W and outer container weld 22W.

The outer container weld 22W may circumscribe the product deliverydevice weld 55, 56W in concentric or eccentric fashion. The outercontainer weld 22W and product delivery device weld 55W, 56W may be ofequal or unequal radial thickness, require equal or unequal energy toeffect a proper bond and may be equally or unequally spaced from theother and equally or unequally spaced about the longitudinal axis.

As determined by the first annular sealing surface 31 circumscribing thesecond annular sealing surface 32, the outer container weld 22W willcircumscribe the product delivery device weld 55W, 56W. The productdelivery device weld 55W, 56W and outer container weld 22W may be in thesame plane or in different planes. It is only important that the productdelivery device weld 55W, 56W and outer container weld 22W, or othersuch respective seal between the product delivery device 55, 56/outercontainer 22 and valve 28 provide a pressure boundary to retain product42 and propellant 40 within the outer container 22.

Without being bound by theory, it is believed that if a dip tube 56 isselected, only one of the product delivery device weld 56 and outercontainer weld 22 need circumscribe the longitudinal axis. The other ofthe product delivery device weld 56 and outer container weld 22 maycomprise one or more discrete welds 22W, 56W which do not circumscribethe longitudinal axis, but merely hold these components in properposition. Of course, any type of seals such as press fit, interferencefit, solvent welding, laser welding, sonic welding, ultrasonic welding,spin welding, adhesive and any combination thereof which maintains thepressure boundary may be used.

The valve 28 is preferably spin welded by rotation about thelongitudinal axis. The valve 28 is subjected to relative motion againstthe outer container 22 and product delivery device 55, 56. The outercontainer 22 and product delivery device 55, 56 may be rotated about thelongitudinal axis and the valve 28 held stationary. Or preferably theouter container 22 and product delivery device 55, 56 are heldstationary and the valve 28 rotated relative thereto. Any difference inrotation between the valve 28 and the outer container 22/productdelivery device 55, 56 which produces sufficient friction to create aleak tight weld for a pressure boundary for the propellant 40 andproduct 42 is suitable.

This arrangement advantageously allows for assembly of any desiredproduct delivery device 55, 56 providing it is sealingly complementaryto the second annular sealing surface 32. This arrangement thenadvantageously allows for subsequent assembly of any desired valve 28,providing it is sealingly complementary to the first annular sealingsurface 31. Thus any combination and variety of bags 55, dip tubes 56and valves 28 may be used with a single outer container 22. Thisarrangement advantageously minimizes production and storage of a varietyof outer containers 22, in lieu of only a single outer container 22being required for any particular size of aerosol dispenser 20.

Referring to FIGS. 8A, 8B and 8C, either or both of the first surface 31and/or second surface 32 may be a sealing surface. By sealing surface itis meant that a valve 28 may be seated upon the first annular sealingsurface 31 without leakage of propellant 40 therebetween to ambient.Likewise, by sealing surface it is meant that a product delivery device55, 56 may be seated upon the second annular sealing surface 32 withoutleakage of propellant 40 therebetween to ambient. It is to be understoodthe first surface 31 may or may not be a first annular sealing surface31 provided adequate seal is elsewhere provided. Likewise, the secondsurface 32 may or may not be a second annular sealing surface 32provided adequate seal is elsewhere provided.

A component complementary to the second annular sealing surface 32 canbe disposed thereon and not interfere, particularly in the longitudinaldirection, with a valve 28 operable by a user when the valve 28 isattached. It is only necessary that the valve 28 fit to the firstsealing surface in operable relationship. This arrangement provides thebenefit that multiple valves 28 may be used with a single outercontainer 22, depending upon the particular product[s] 42 desired.

Likewise, multiple components may be disposed on the second annularsealing surface 32, so long as such second component remains below thevalve 28. The second component may be a bag 55 or a dip tube 56.

The first annular sealing surface 31 may be concentric to thelongitudinal axis and frustroconical, as shown. This arrangementprovides the benefit that a valve 28 disposed thereon will seat to thelowest point, i.e. having the smallest diameter. The valve 28 isdisposed in the proper position without a separate step required in themanufacturing process.

The second annular sealing surface 32 may be concentric andperpendicular to the longitudinal axis and annular, as shown. Thisarrangement provides the benefit that a component disposed thereon willseat concentric and below the first sealing surface 32. The productdelivery device 55, 56 is disposed in the proper place without aseparate step required in the manufacturing process. The productdelivery device 55, 56, or other component, is installed and seatedbefore the valve 28 is inserted.

If desired, the first annular sealing surface 31 and second annularsealing surface 32 may be contiguous. This arrangement provides thebenefit that the first annular sealing surface 31 and second annularsealing surface 32 need not be separately assembled duringmanufacturing, simplifying production and reducing the opportunity formistakes. More particularly, in one preferred embodiment the firstannular sealing surface 31 and second annular sealing surface 32 may bemutually integral and integral with the outer container 22. Thisarrangement provides the benefit of ease of manufacture, by eliminatingunnecessary assembly of multiple parts.

In each of the foregoing embodiments, the first annular sealing surface31 and second annular sealing surface 32 are generally contiguous in theabsence of seal. But the first annular sealing surface 31 and secondannular sealing surface 32 may be longitudinally spaced apart withoutdeparture from the invention claimed herein. The first annular sealingsurface 31 and second annular sealing surface 32 may be mutually skewedor mutually parallel in a degenerate case. If desired, threads 25 mayalso be used to assist in component assembly.

If desired, two or more product delivery devices 55, 56 may be used withthe aerosol dispenser 20 of the present invention. Such plural productdelivery devices 55, 56 may include one or more bags 55, one or more diptubes 56 or any combinations thereof. The plural product deliverydevices may be coaxial or parallel. This arrangement provides thebenefit that plural products 42 may be co-dispensed, but not intermixeduntil the point of use.

Referring to FIGS. 8A, 8B and 8C, the foregoing aerosol dispensers 20,outer containers 22 and preforms 60, may have a transition 34 betweenthe first annular sealing surface 31 and the second annular sealingsurface 32. The transition 34 is any discernable break dividing thefirst annular sealing surface 31 and the second annular sealing surface32. Of course there may be three or more sealing surfaces 31, 32, havingrespective transitions, 34, providing the sealing surfaces 31, 32 areappropriately sized. The transitions 34 provide the benefit that each ofthe first annular sealing surface 31 and second annular sealing surface32 can be specifically tailored to its particular function of sealinglyretaining the valve 28 and product delivery device 55, 56, respectively.

Referring to FIGS. 8A-8C, the transition 34 may comprise a step betweenthe first annular sealing surface 31 and the second annular sealingsurface 32. The step may be a longitudinal break, between a mutuallyparallel or mutually skewed first annular sealing surface 31 and secondannular sealing surface 32.

Referring to FIG. 9, an aerosol dispenser 20 according to the presentinvention need not have a transition 34 between the first annularsealing surface 31 and the second annular sealing surface 32. It is thebenefits of the present invention to provide a chassis for multiplecombinations of valves 28 and product delivery devices 55, 56 using thefirst annular sealing surface 31 and the second annular sealing surface32.

The first annular sealing surface 31 and second annular sealing surface32 may each be disposed generally perpendicular to the longitudinalaxis, provided the second annular sealing surface 32 still has a smallerdiameter SSD than the diameter FSD of the first annular sealing surface31. This arrangement provides the benefit that the peripheries of thefirst annular sealing surface 31 and second annular sealing surface 32may prevent undue radial movement of the valve 28 and product deliverydevice 55, 56, respectively. It is to be understood that the embodimentsof, for example, FIG. 9 has first annular sealing surface 31 and secondannular sealing surface 32 in contiguous relationship and uninterruptedby an optional seal.

The first surface may have a diameter FSD of 7 to 23 mm and preferably10 to 20 mm. The threads 25 may have a diameter VAD of 10 to 30 mm, andpreferably 15 to 25 mm. A thread 25 diameter VAD of 18.3 mm and a firstsurface 30 diameter VAD of 13.6 mm have been found suitable. The firstannular sealing surface 31 may be longitudinally disposed at least 1 mm,particularly 1 to 5 mm below the lowest thread 25. The second annularsealing surface 32 may have a diameter SSD less than the threads 25 orother valve attachment diameter VAD and greater than the first sealingsurface 32 diameter FSD.

The absence of an optional transition 34, or a bead seal, provides thebenefit of manufacturing flexibility, to accommodate valve 28 andproduct delivery device 55, 56 of different radial and longitudinaldimensions. While first annular sealing surface 31 and second annularsealing surface 32 are shown to be in specific and fixed inrelationship, one of skill will recognize the invention is not solimited. Utilizing a preform 60/outer container 22/aerosol dispenser 20according to these and like embodiments offers manufacturing flexibilitynot previously found in the art. These embodiments allow themanufacturer to select a number of suitable valves 28, so long as theyfit onto the first annular sealing surface 31.

A first valve 28, suitable for a first product 42, may have a firstannular footprint on first annular sealing surface 31. A second valve28, suitable for a second product 42, may have a second, and different,annular footprint on first annular sealing surface 31, etc. The chassisprovided by the preform 60/outer container 22/aerosol dispenser 20provides this flexibility for multiple valves 28, provided thatsufficient footprint is available on second annular sealing surface 32to accommodate the product delivery device 55, 56.

Thus a product delivery device 55, 56, suitable for a first product 42,may have a first annular footprint on second annular sealing surface 32.A second product delivery device 55, 56, suitable for a second product42, may have a second, and different, annular footprint on secondannular sealing surface 32, etc. The chassis provided by the preform60/outer container 22/aerosol dispenser 20 provides this flexibility formultiple The chassis provided by the preform 60/outer container22/aerosol dispenser 20 provides this flexibility for multiple valves28, provided that sufficient footprint is available on second annularsealing surface 32 to accommodate the product delivery devices 55, 56,provided that sufficient footprint is available on first annular sealingsurface 31 to accommodate the valve 28.

If desired, the valve 28 may be stacked on and overlap bag 55/dip tube56. This arrangement provides the benefit of a common seal annulus andincreased flexibility in sizing the valve 28/bag 55/dip tube 56.

If desired, the valve 28 may be attached to an optional valve cup 26.Optionally the product delivery device 55, 56, particularly a bag 55 ordip tube 56, may be attached to, and more particularly integrallyattached to, the valve cup 26. A suitable configuration is disclosed incommonly assigned P&G Case 14461, application Ser. No. 15/235,279, filedAug. 12, 2016, particularly as disclosed in FIGS. 1C-1D thereof.

Referring to FIG. 10, alternatively, the product delivery deviceprotrusion 55E, 56E may project upwardly from the product deliverydevice 55, 56. Likewise the outer container protrusion 22E may projectupwardly from the outer container 22. One of skill will recognize that acombination of a product delivery device protrusion 55E, 56E and anouter container protrusion 22E with one projecting upward, the otherdownward is also feasible and within the scope of the invention.

Referring to FIGS. 11A-11B, the preform 60 and outer container 22 formedtherefrom may have divots 61 therein. The divots 61 are gripped by thewelding equipment during the welding step, and minimize or preventrotation of the outer container 22 during the welding step. Likewise,divots 61 may be incorporated between the outer container 22 and theproduct delivery device 55, 56 to prevent rotation therebetween. Thisarrangement allows for relative movement between the valve 28 and theouter container 22/the product delivery device 55, 56 if spin welding isthe step selected to join these components.

Referring particularly to FIG. 11B, an external drive 70 may be used toprovide relative motion between the valve 28 and the product deliverydevice 55, 56/outer container 22. The external drive 70 may bevertically actuated to engage blades 28B, then vertically retracted.Likewise chuck 72 may be vertically actuated to engage divots 61, whichprovide torque counter to the external drive 70. Upon welding, the valve28 may axially move downward a distance H, corresponding to the meltingof the protrusions 22E, 55E.

FIG. 12 shows an image of a vertical section view of an outer container22, valve 28, and product delivery device 55, 56 before welding. Withreference to FIGS. 13-15, after spin-welding, outer container weld 22Wand product delivery device weld 55W, 56W may be formed. As shown inFIGS. 13-15, as the weld depth increases, the size of the outercontainer weld 22W and the product delivery device weld 55W, 56Wincreases and the greater portion of the outer container, valve, andproduct delivery device that are melted and welded together. Weldingprovides additional structural strength to retain the valve andreinforce the neck of the bottle. Moreover, as shown in FIGS. 13-15,welding causes the melted material to fill all or a portion of the gapsbetween the outer container 22, valve 28, and product delivery device55, 56. The greater the weld depth, the more the gaps may be filled bymelted material.

Referring back to FIGS. 3A-3B, the bag 55 may be integrally injectionmolded with the valve cup 26. If the preform 60 is to be stretched intoa bag 55, the preform 60 may have a wall thickness of 1 to 3 mm. Theresulting bag 55 is collapsible upon depletion of product 42 therefrom.The resulting bag 55 may have a thickness of 0.07 to 0.2 mm.

If desired, the outer container 22 and propellant 40 may be assembled ata first location. The product 42, decoration, etc. may be added at asecond location, as described in commonly assigned 2012/0292338 and2012/0291911.

Thus, the aerosol dispenser 20 may be made by providing nested preforms60 comprising an outer preform 60 and inner preform 60 disposed therein.The inner preform 60 has a valve cup 26 at the open end thereof.

The preforms 60 are blowmolded together to form an outer container 22and having an open end and an inner bag 55 depending therefrom towardsthe closed end of the outer container. Propellant 40 is charged betweenthe bag 55 and outer container 22. The valve cup 26 is sealing joined tothe open end of the outer container 22 to contain the propellant 40therein and form an aerosol container 20C. The aerosol container 20C maythen be stored as needed or directly shipped for product 42 fill,installing the valve 28, actuator 29, label 57, etc.

Alternatively, an integral inner bag 55/valve cup 26 combination may beprovided and inserted into an outer container 22. The inner bag 55 isinserted in the open end of the outer container 22. Propellant 40 ischarged between the bag 55 and outer container 22. The integral valvecup 26 is sealingly joined to the open end of the outer container 22 tocontain the propellant 40 therein and form an aerosol container 20C. Theaerosol container 20C may then be stored as needed or directly shippedfor product 42 fill, installing the valve 28, actuator 29, label 57,etc. In either alternative, the inner preform 60 may have a neck 24according to the present invention, with the first annular sealingsurface 31 and second annular sealing surface 32 as described andclaimed herein.

Each embodiment described above has an aerosol container having alongitudinal axis and comprising an outer container comprising a closedend bottom and an open neck longitudinally opposed thereto. While thepreferred invention has been described in terms of a product deliverydevice weld 55W, 56W and an outer container weld 22W, the invention isnot so limited. The open neck 24 may have a valve 28 sealed to the outercontainer 22 in fluid tight relationship by any suitable outer containerseal 22W. Likewise, the product delivery device 55, 56 may be sealed tothe valve 28 in fluid tight relationship by any suitable productdelivery device seal 55, 56W. The product delivery device seal 55, 56Wis radially spaced apart from, and preferably inward of, the outercontainer seal 22W.

Suitable outer container seals 22W and suitable product delivery deviceseals 55, 56W include a press fit, interference fit, adhesive, solventwelding, laser welding, sonic welding, ultrasonic welding, preferablyspin welding, or any combination thereof. An intermediate component,such as a sleeve or connector may optionally be disposed intermediate toform the outer container seals 22W and suitable product delivery deviceseals 55, 56W Any such arrangement is suitable, so long as a permanentseal adequate to maintain the pressure results.

Generally polymeric components are preferred, for the outer container22, valve 28 and product delivery device 55, 56. PET has been found tobe particularly preferred. PET is suitable for preferred sealing asdescribed below.

Of the various sealing processes described above, welding has been foundto be preferred, and spin welding has been found to be particularlypreferred. Spin welding provides the unpredicted benefit ofconcentrating the energy input near the outer container seal 22W andproduct delivery device seal 55, 56W, thereby minimizing wasted energy,and minimizing extraneous energy directed downward where damage to theproduct delivery device 55, 56 may result. Spin welding further providesthe unpredicted benefit of forming the outer container seal 22W andproduct delivery device seal 55, 56W in a single operation.

While the outer container seals 22W and product delivery device seals55, 56W are shown to be mutually concentric and concentric to thelongitudinal axis, the invention is not so limited. The outer containerseal 22W and product delivery device seal 55, 56W may be of constant orvariable thickness in the radial direction, in the same plane ormutually different planes with either being above or below the other,may be formed by the same process or different processes, may beperpendicular to or skewed to the longitudinal axis, mutually eccentricand/or eccentric to the longitudinal axis, and be within the scope ofthe appended claims.

While a round outer container 22 is described, the invention is not solimited. The outer container 22, and thus the valve attachment, firstannular sealing surface 31 and second annular sealing surface 32 may beof any desired shape so long as the circumference of the second annularsealing surface 32 is less than and interior to the circumference of thefirst annular sealing surface 31 which in turn is less than and interiorto the circumference of the valve attachment circumference. Preferablythe valve attachment circumference, first annular sealing surface 31circumference and second annular sealing surface 32 circumference areconcentric.

In one embodiment, one of skill will recognize that a single outercontainer 22 may be used with n₁ different valves, properly sized to thevalve attachment diameter VAD, with n₂ bags 55 and with n₃ dip tubes 56.This embodiment provides multiple formats, and n₁×n₂×n₃ differentcombinations of formats which may be advantageously used with a singleouter container 22. Thus a single outer container 22 provides a chassisfor n₁×n₂×n₃ different aerosol dispensers 20. Manufacturing complexityis reduced and flexibility increased using the present invention.

Thus a suitable embodiment is to use a single outer container 22 withany number of desired valves 28. Regarding the valve 28, it is onlynecessary that each valve 28 fit into the first annular sealing surface31 and functionally dispense the product 42. Likewise regarding theproduct delivery device 55, 56, it is simply necessary that each productdelivery device 55, 56 fit into the second annular sealing surface 32and functionally dispense the product 42. Thus a bag 55 need only have acollar 55C and a dip tube 56 need only have a dip tube collar 56C whichsealingly fits onto the second annular sealing surface 32. Of course,the product delivery device 55, 56 and valve 28 should not interferewith each other during assembly and use.

The invention comprises various embodiments and combinations, as setforth below in exemplary, non-limiting manner. It is to be understoodthat any of the variations, and combinations listed in each of theembodiments for the outer container 22, aerosol container 20C aerosoldispenser 20 and/or preform 60 may be used for any other such embodimentwithout limitation.

-   -   A. A method of making an aerosol container 20C, said method        comprising the steps of:        providing a polymeric outer container 22 having a closed end        bottom and an open neck 24 longitudinally opposed thereto, a        valve 28 and a product delivery device 55, 56, said valve 28 and        said product delivery device 55, 56 being complementary to said        open neck 24,        disposing said product delivery device 55, 56 in said outer        container 22 and in contacting relationship with said neck 24,        disposing said valve 28 at least partially in said outer        container 22 and in contacting relationship with said neck 24        and said product delivery device 55, 56,        spinning said valve 28 relative to said product delivery device        55, 56 to weld said valve 28 to said product delivery device 55,        56 at a product delivery device spin weld 55, 56W,        charging said outer container 22 with propellant 40, and        spinning said valve 28 relative to said outer container 22 to        weld said valve 28 to said outer container 20 at an outer        container spin weld 22W, thereby sealing said propellant 40        therein.    -   B. A method according to paragraph A wherein said steps of        spinning said valve 28 relative to said product delivery device        55, 56 and spinning said valve 28 relative to said outer        container 22 are performed simultaneously.    -   C. A method according to paragraphs B and C wherein said product        delivery device weld 55, 56W is completed before said outer        container weld 22W is completed.    -   D. A method according to paragraphs A, B and C and wherein said        valve 28 has a product delivery device protrusion 55, 56E        fitting onto a sealing surface 31 on said product delivery        device 55, 56 and an outer container protrusion 22E fitting onto        a sealing surface 31 in said outer container 22, said product        delivery device spin weld 55, 56W and said outer container spin        weld 22W being formed at said respective protrusions 55, 56E,        22E.    -   E. A method according to paragraphs A, B, C and D wherein said        valve 28 has a product delivery device protrusion 55, 56E        fitting onto a sealing surface 32 on said product delivery        device 55, 56 and an outer container protrusion 22E fitting onto        a sealing surface 31 in said outer container 22, said product        delivery device spin weld 55, 56W and said outer container spin        weld 22W being formed at said respective protrusions 55, 56E and        22E, said product delivery device protrusion 55, 56E contacting        said valve 28 before said outer container protrusion 22E        contacts said valve 28.    -   F. A method according to paragraphs A, B, C, D and E wherein        said outer container 22 is held axially stationary during said        welding step.    -   G. A method of making an aerosol dispenser 20, said method        comprising the steps of:        providing a polymeric outer container 22 having a closed end        bottom and an open neck 24 longitudinally opposed thereto, a        polymeric valve 28 and a polymeric product delivery device 55,        56, said valve 28 and said product delivery device 55, 56 being        complementary to said open neck 24,        disposing said product delivery device 55, 56 in said outer        container 22 and in contacting relationship with said neck 24,        disposing said valve 28 at least partially in said outer        container 22 and in contacting relationship with said neck 24        and said product delivery device 55, 56,        joining said valve 28 to said product delivery device 55, 56 in        fluid tight relationship at an annular product delivery device        seal 55, 56W,        charging said outer container 22 with propellant 40,        charging product 42 into said aerosol dispenser 20,        joining said valve 28 to said outer container 22 in fluid tight        relationship at an annular outer container seal 22W        circumscribing said annular product delivery device seal 55,        56W, thereby sealing said propellant 40 therein,        disposing an actuator 29 on said aerosol dispenser 20 in        operable relationship with said valve 28, whereby said actuator        29 can open said valve 28 as desired by a user, and        decorating said outer container 22 with indicia 57.    -   H. A method according to paragraph G wherein said product        delivery device 55, 56 comprises a dip tube 56, and said step of        charging said outer container 22 with propellant 40 occurs        before said step of charging with product 42, and said step of        charging with product 42 occurs through said dip tube 56.    -   I. A method according to paragraphs G and H wherein said product        delivery device 55, 56 comprises a dip tube 56, and said step of        charging said outer container 22 with propellant 40 occurs        concurrent with said step of charging with product 42, and said        step of charging with product 42 and propellant 40 occurs to        said product delivery device 55, 56.    -   J. A method according to paragraphs G, H and I wherein said        product delivery device 55, 56 comprises a dip tube 56, and said        step of charging said outer container 22 with propellant 40        occurs concurrent with said step of charging with product 42,        and said step of charging with product 42 and propellant 40        occurs, and further comprising the step of welding contain said        product 42 and said propellant 40 in said outer container.    -   K. A method according to paragraphs G, H, I and J wherein said        step of joining said valve 28 to said product delivery device        55, 56 comprises welding said valve 28 to said product delivery        device 55, 56.    -   L. A method according to paragraphs G, H, I, J and K wherein        said step of joining said valve 28 to said outer container 22        comprises welding said valve 28 to said outer container 55, 56.    -   M. A method according to paragraphs G, H, I, J, K and L wherein        said step of joining said valve 28 to said product delivery        device 55, 56 and to said outer container 22 comprises welding        said valve 28 to said product delivery device 55, 56 and to said        outer container 22.    -   N. A method according to paragraphs G, H, I, J, K, L and M        wherein said step of joining said valve 28 to said product        delivery device 55, 56 and to said outer container 22 comprises        spin welding said valve 28 to said product delivery device 55,        56 and to said outer container 22.    -   O. A method according to paragraphs G, H, I, J, K, L, M and N        wherein said step of charging product 42 comprises charging with        product 42 selected from the group consisting of air treatment,        shaving cream, shaving foam, insecticide and cleansers.    -   P. A method of making an aerosol container 20C having a        longitudinal axis, said method comprising the steps of:        providing a polymeric outer container 22 having a closed end        bottom and an open neck 24 longitudinally opposed thereto, a        polymeric valve 28 and a polymeric product delivery device 55,        56, said valve 28 and said product delivery device 55, 56 being        complementary to said open neck 24,        disposing said product delivery device 55, 56 in said outer        container 22 and in contacting relationship with said neck 24,        disposing said valve 28 at least partially in said outer        container 22 and in contacting relationship with said neck 24        and said product delivery device 55, 56,        sealingly joining said valve 28 to said product delivery device        55, 56 with a product delivery device seal 55, 56W, and        sealingly joining said valve 28 to said outer container 22 at an        outer container seal 22W, said outer container seal 22W being        radially outboard of said product delivery device seal 55, 56W.    -   Q. A method according to paragraph P wherein said product        delivery device 55, 56 comprises a bag 55 and said steps of        sealingly joining said valve 28 to said product delivery device        55, 56 comprises sealing joining with a product delivery device        seal 55, 56 W that circumscribes said longitudinal axis and        sealingly joining said valve 28 to said outer container 22        comprises sealing joining with an outer container seal 22W that        circumscribes said longitudinal axis.    -   R. A method according to paragraphs P and Q wherein said product        delivery device 55, 56 comprises a bag 55 and said steps of        sealingly joining said valve 28 to said product delivery device        55, 56 comprises first sealing joining said valve 28 to said        product delivery device 55, 56 with a product delivery device        seal 55, 56W that circumscribes said longitudinal axis and then        sealingly joining said valve 28 to said outer container 22        comprises sealingly joining said outer container 22 with an        outer container seal 22W that circumscribes said longitudinal        axis.    -   S. A method according to paragraph P wherein said product        delivery device 55, 56 comprises a dip tube 56 and said steps of        sealingly joining said valve 28 to said product delivery device        55, 56 comprises sealingly joining with a product delivery        device seal 55, 56W that circumscribes said longitudinal axis        and sealingly joining said valve 28 to said outer container 22        comprises sealing joining with an outer container seal 22W that        circumscribes said longitudinal axis, and further comprising the        step of simultaneously charging said outer container 22 with        product 42 and propellant 40 in a predetermined ratio.    -   T. A method according to paragraphs P and S wherein said product        delivery device 55, 56W comprises a dip tube 56 and said steps        of sealingly joining said valve 28 to said product delivery        device 55, 56 and sealingly joining said valve 28 to said outer        container 22 comprises sealingly joining only one of said        product delivery device 55, 56 and said valve 28 with a seal        22W, 55, 56W that circumscribes said longitudinal axis.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm” and a pressure disclosed as “about 1100 kPa” is intendedto include 1103.2 kPa.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern. All limits shown herein as defining a range may be used with anyother limit defining a range. That is the upper limit of one range maybe used with the lower limit of another range, and vice versa.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of making an aerosol container, saidmethod comprising: providing a polymeric outer container having a closedend bottom and an open neck longitudinally opposed thereto, a valve anda product delivery device, said valve and said product delivery devicebeing complementary to said open neck, disposing said product deliverydevice in said outer container and in contacting relationship with saidneck, disposing said valve at least partially in said outer containerand in contacting relationship with said neck and said product deliverydevice, spinning said valve relative to said product delivery device toweld said valve to said product delivery device at a product deliverydevice spin weld, charging said outer container with propellant, andspinning said valve relative to said outer container to weld said valveto said outer container at an outer container spin weld, thereby sealingsaid propellant therein, wherein said valve has a product deliverydevice protrusion fitting onto a sealing surface on said productdelivery device and an outer container protrusion fitting onto a sealingsurface in said outer container, said product delivery device spin weldand said outer container spin weld being formed at said respectiveprotrusions.
 2. The method according to claim 1, wherein spinning saidvalve relative to said product delivery device and spinning said valverelative to said outer container are performed simultaneously.
 3. Themethod according to claim 1, wherein said product delivery device weldis completed before said outer container weld is completed.
 4. Themethod according to claim 1, wherein said product delivery deviceprotrusion contacting said valve before said outer container protrusioncontacts said valve.
 5. The method according to claim 1, wherein saidouter container is held axially stationary during said spinning steps.6. A method of making an aerosol dispenser, said method comprising:providing a polymeric outer container having a closed end bottom and anopen neck longitudinally opposed thereto, a polymeric valve and apolymeric product delivery device, said valve and said product deliverydevice being complementary to said open neck, disposing said productdelivery device in said outer container and in contacting relationshipwith said neck, disposing said valve at least partially in said outercontainer and in contacting relationship with said neck and said productdelivery device, wherein said valve has a product delivery deviceprotrusion fitting onto a sealing surface on said product deliverydevice and an outer container protrusion fitting onto a sealing surfacein said outer container, joining said valve to said product deliverydevice in fluid tight relationship at an annular product delivery deviceseal, charging said outer container with propellant, charging productinto at least one of said outer container and said product deliverydevice, joining said valve to said outer container in fluid tightrelationship at an annular outer container seal circumscribing saidannular product delivery device seal, thereby sealing said propellanttherein, wherein said product delivery device seal and said outercontainer seal being formed at said respective protrusions, disposing anactuator on said aerosol dispenser in operable relationship with saidvalve, whereby said actuator can open said valve as desired by a user,and decorating said outer container with indicia.
 7. The methodaccording to claim 6, wherein said product delivery device comprises adip tube, and charging said outer container with propellant occursbefore charging with product, and charging with product occurs throughsaid dip tube.
 8. The method according to claim 6, wherein said productdelivery device comprises a dip tube, and charging with propellantoccurs concurrent with charging with product.
 9. The method according toclaim 6, wherein joining said valve to said product delivery devicecomprises welding said valve to said product delivery device.
 10. Themethod according to claim 6, wherein joining said valve to said outercontainer comprises welding said valve to said outer container.
 11. Themethod according to claim 6, wherein joining said valve to said productdelivery device and to said outer container comprises welding said valveto said product delivery device and to said outer container.
 12. Themethod according to claim 6, wherein joining said valve to said productdelivery device and to said outer container comprises spin welding saidvalve to said product delivery device and to said outer container. 13.The method according to claim 6, wherein charging product comprisescharging with product selected from the group consisting of airtreatment, shaving cream, shaving foam, insecticide and cleansers.
 14. Amethod of making an aerosol container having a longitudinal axis, saidmethod comprising: providing a polymeric outer container having a closedend bottom and an open neck longitudinally opposed thereto, a polymericvalve and a polymeric product delivery device, said valve and saidproduct delivery device being complementary to said open neck, disposingsaid product delivery device in said outer container and in contactingrelationship with said neck, disposing said valve at least partially insaid outer container and in contacting relationship with said neck andsaid product delivery device, wherein said valve has a product deliverydevice protrusion fitting onto a sealing surface on said productdelivery device and an outer container protrusion fitting onto a sealingsurface in said outer container, sealingly joining said valve to saidproduct delivery device with a product delivery device seal, andsealingly joining said valve to said outer container at an outercontainer seal, said outer container seal being radially outboard ofsaid product delivery device seal, wherein said product delivery deviceseal and said outer container seal being formed at said respectiveprotrusions.
 15. The method according to claim 14, wherein said productdelivery device comprises a bag and sealingly joining said valve to saidproduct delivery device comprises sealingly joining with a productdelivery device seal that circumscribes said longitudinal axis andsealingly joining said valve to said outer container comprises sealinglyjoining with an outer container seal that circumscribes saidlongitudinal axis.
 16. The method according to claim 14, wherein saidproduct delivery device comprises a bag and sealingly joining said valveto said product delivery device comprises first sealingly joining saidvalve to said product delivery device with a product delivery deviceseal that circumscribes said longitudinal axis and then sealinglyjoining said valve to said outer container comprises sealingly joiningsaid outer container with an outer container seal that circumscribessaid longitudinal axis.
 17. The method according to claim 14, whereinsaid product delivery device comprises a dip tube and sealingly joiningsaid valve to said product delivery device comprises sealingly joiningwith a product delivery device seal that circumscribes said longitudinalaxis and sealingly joining said valve to said outer container comprisessealingly joining with an outer container seal that circumscribes saidlongitudinal axis, and further comprising simultaneously charging saidouter container with product and propellant in a predetermined ratio.18. The method according to claim 14, wherein said product deliverydevice comprises a dip tube and sealingly joining said valve to saidproduct delivery device and sealingly joining said valve to said outercontainer comprises sealingly joining only one of said product deliverydevice and said valve with a seal that circumscribes said longitudinalaxis.